Brass Wire Electrode Research Articles

Studying Performance of Wire Electrical Discharge Machining for Multi-pass Cutting Strategy on the Tool Steel SKD 61 Using Recommended Parameters of Machine

This research aims to study the machining efficiency of wire electrical discharge machining for multi-pass cutting. The recommended parameters of the machine are employed for cutting test tool steel grade SKD 61 with the thickness of 40 mm. The brass wire electrode with the diameter of 0.25 mm was used in the cutting test. The recommended parameters for multi-pass tool path cutting consisted of 4 operations. The 1st cut was defined as a full cut that required the removal of a large amount of workpiece material, with the cutting speed set at 2.60 mm/min. The 2nd, 3rd, and 4th cuts involve cutting on the edge of the workpiece to remove only a small amount of work material, with the cutting speed set at 3.20, 3.60, and 6.80 mm/min, respectively. The experimental test showed that the machining performance of the cutting speed for the 1st cut was lower than the expected value by approximately 18.01 percent. The 2nd, 3rd, and 4th cuts found that the cutting speed higher than expected value by approximately 104.34, 128.89 and 4.12 percentage for each cutting pass, respectively. In addition, the surface roughness and dimensional error of the machined part decrease as the number of cutting passes increases. The difference between the expected values and the experimental results is very useful in planning decisions and quality control for cutting workpieces by the process of wire electrical discharge machining.

Experimental Investigation on Wire Electric Erosion Behaviour of Silicon Dioxide Particulate Reinforced Composite

The intend of current study was focused on the prediction of material removal rate (MRR) and surface roughness (SR) for the AA7050-SiO2 composite during wire electric erosion or discharge machining (WEDM) process using a brass (Br) wire electrode. Here, stir casting process was employed to develop the AA7050 matrix composite with inclusion of 10wt.% SiO2 particle reinforcement. The multi-objective optimization method of Technique for order preference by similarity to ideal solution (TOPSIS) approach has been applied to find out the optimal setting of input machining parameters such as peak current (Ip), pulse-on time (Ton) and pulse-off time (Toff). Furthermore, the significant effects of parameters were identified by analysis of variance (ANOVA). Taguchi L9 (33) orthogonal design has been formulated to perform the experimental work. TOP SIS results stated that the optimal setting of Ip at 30 amps, Ton of 130 μs and Toff of 55 μs provide the better MRR with lesser SR. The ANOVA results noticed that Ip has the prime noteworthy parameter over the adopted responses having a contribution of 45.67%, followed by Ton (32.34%) and Toff (12.26%), respectively. The confirmation test was carried out by the optimal parameters setting to verify the predicted results. Finally, the scanning electron microscopy (SEM) test was carried out for the machined surface of the composite specimen and it was reveals that the formation of craters and recast layer thickness in the machined surfaces.

EXPERIMENTAL STUDY ON WIRE ELECTRIC DISCHARGE MACHINING OF NIMONIC 90 USING COATED ELECTRODE

Abstract WEDM machine is an unconventional machine that got accepted in the industries because of its skill to machine any material precisely in the required shape and size. Wire electric discharge machine uses electrical energy to cut hard conductive materials. In the present study, Nimonic 90 a nickel-based superalloy is machined in WEDM using a zinc-coated brass wire electrode to study its surface characteristics and its machinability. Experiments were carried out with central composite design with controllable WEDM factors such as Pulse duration, Servo-voltage, and wire-tension were used to investigate machining performance such as material transfer rate (MRR) and average surface roughness (Ra).The second order quadratic models are developed between WEDM parameters and responses by regression analysis. Analysis of Variance was employed to validate the accuracy of the established statistical models and the impact of the process variables. The RSM based optimization was used to find the optimal process parameter of Wire Tension 11.962 N, Pulse on Time 79.785 µs and Servo Voltage 100 V to achieve maximum MRR of 5.3574 (mm3/min) and minimal Ra of 2.6513 (μm). The validity of the optimized values are verified by conducting confirmation experiments and found that errors are within the permissible limit. Further, the surface morphology of the WEDMed specimen was carried out through SEM to ascertain the mechanisms of material removal under the different settings of WEDM.

Experimental investigation of wire electrical discharge machining parameters on WE43 magnesium alloy

The influence of wire electrical discharge machining (WEDM) factors on the WE43 magnesium alloy is experimentally investigated in this work. Voltage, peak current, pulse-on time, and pulse-off time, are some of the factors taken into consideration in the study. The goal of the study is to understand how the output responses like material removal rate (MRR), surface roughness (SR), and development of recast layers are affected by the factors like voltage, peak current, pulse-on time and pulse-off time. The experimental set-up used a wire electrical discharge machine with a brass wire electrode and a workpiece made of the WE43 magnesium alloy. The L27 orthogonal array was used to alter the selected parameters through a series of experiments. The findings of the experimental investigation showed a strong link between the output responses and the electrical discharge machining (EDM) parameters. Peak current was discovered to have a direct correlation with the rate of material removal, with greater currents resulting in faster machining. SR and MRR were affected by pulse-on time and pulse-off time. Voltage had a direct impact on the development and thickness of the recast layer, with higher voltages favoring thinner recast layers.

Enhancing Wire-EDM Performance with Zinc-Coated Brass Wire Electrode and Ultrasonic Vibration

This study aimed to investigate the performance of zinc-coated brass wire in wire-cut electrical discharge machining (EDM) using an ultrasonic-assisted wire on tungsten carbide. The research focused on the effect of the wire electrode material on the material removal rate, surface roughness, and discharge waveform. Experimental results demonstrated that using ultrasonic vibration improved the material removal rate and reduced surface roughness compared to conventional wire-EDM. Cross-sectional SEM of the white layer and discharge waveform were investigated to explain the phenomena of ultrasonic vibration in the wire-cut EDM process.

Investigations on the wire EDM characteristics of Al matrix composite using TOPSIS method

This study deals with wire electrical discharge machining (WEDM) of alumina (Al2O3) reinforced AA6063 matrix composite using a brass wire electrode to analyze the two important characteristics concerning material removal rate (MRR) and surface roughness (Ra). Nine combinations of experimental runs are performed by taking three input parameters (peak current (Ip), pulse-on time (Ton) and pulse-off time (Toff)) based on Taguchi’s design of experiments. In addition, Technique for order preference by similarity to ideal solution is employed for multi-response optimization. Thereafter, analysis of variance (ANOVA) is employed to determine the influence of parameters on responses. From TOPSIS results identified that the optimal parameters for obtain the higher MRR and lower Ra are ‘Ip’ of 20A, ‘Ton’ of 100 µs and ‘Toff’ of 30 µs, respectively. ANOVA result revealed that ‘Ton’ has the main significant factor (42.40 %) in enhancement of MRR and deprivation of Ra, followed by ‘Ip’ (28.53 %) and ‘Toff’ (16.63 %), respectively.

WEDM ile Kesilen Sleipner Soğuk İş Çeliğinin Kesim Kalitesine Pirinç ve Bakır Tel Kullanımının Etkileri

Wire electric discharge machining (WEDM) is widely used in dies, punches, aerospace and automotive sectors, since materials with high hardness, and temperature resistant, which are not possible to be cut with conventional machining methods, can be cut with high precision using the WEDM method. In this study, cutting speed (mm/min), material removal rate (mm3/min), wire consume (g), machining time (sec), finish measure (mm) and surface roughness (µm) changes as a result of cutting high hardness cold work tool steel using copper and brass wire in WEDM method were investigated. In addition, worn wire and workpiece residues on the machined surfaces were detected by SEM (Scanning Electron Microscope) and EDX (Energy Dispersive X-Ray) analyzes as well as topography and composition were examined. In the case of using copper wire instead of the brass wire, wire consumption and processing time decreased by 23.30 % and 66.29 %, respectively, while MRR increased by 50 % because the copper wire electrode has higher electrical and thermal conductivity than brass wire electrode. In addition, the average dimensional deviation of the parts cut with copper wire decreased from 27 μm to 8 μm compared to the use of brass electrodes, and more precise measurements were obtained.

Surface roughness modeling using machine learning approaches for wire electro-spark machining of titanium alloy

PurposeIn the present study, wire electro-spark machining of Titanium alloy is performed with the machining parameter such as spark-on time, spark-off time, current and servo voltage. The purpose of this study is to model surface roughness using machine learning approach for input/controllable variable. Machined surface examined using scanning electron microscope (SEM) and XRD methods.Design/methodology/approachFull factorial approach has been used to design the experiments with varying machining parameters into three-level four factors. Obtained surface roughness was modeled using machine learning methods namely Gaussian process regression (GPR) and support vector machine (SVM) methods. These methods were compared for both training and testing data with a coefficient of correlation and root mean square error basis. Machined surface examined using scanned electron microscopy and XRD for surface quality produced and check migration of tool material to workpiece material.FindingsMachine learning algorithms has excellent scope for prediction quality response for the wire electric discharge machining (WEDM) process, resulting in saving of time and cost as it is difficult to find each time experimentally. It has been found that the proposed model with minimum computational time, provides better solution and avoids priority weightage calculation by decision-makers.Originality/valueThe proposed modeling provides better predication about surface produced while machining of Ti6Al7Nb using zinc-coated brass wire electrode during WEDM operation.

Optimization of Wire EDM Process Parameters on Cutting Inconel 718 Alloy with Zinc-Diffused Coating Brass Wire Electrode Using Taguchi-DEAR Technique

Inconel 718 alloy has a wide range of applications in the aerospace sector because of its superior mechanical properties and its weldability. The machining of such higher strength materials with complex shapes is possible with wire electrical discharge machining. In the present research, an endeavor was made to enhance the machining process by utilizing zinc-diffused coating brass wire electrode and Taguchi-Data Envelopment Analysis-based Ranking (DEAR) methodology in the process while machining Inconel 718 alloy. Material removal rate, kerf width, and surface roughness were considered as the quality measures. The optimal arrangement of input factors in the Wire Electrical Discharge Machining (WEDM) process were found as 140 µs (Ton), 50 µs (Toff), 60 V (SV), and 5 kg (WT) among the elected factors with the error accuracy of 1.1%. The pulse-off time has the most significance on formulating the quality measures owing to its importance on deionization in the process.

Experimental investigation and prediction modelling of slicing speed and surface roughness during wafer slicing using WEDM

To keep up with the rising demand for silicon solar cells in the photovoltaic sector, an alternative slicing method that can achieve high throughput with minimal waste is required. In recent research efforts, Wire electro-discharge machining (WEDM) has become the possible alternative method for slicing. The experimental investigation focuses on slicing monocrystalline silicon using the WEDM process with a brass wire electrode of 250 μm in diameter. The face-centered central composite design was employed for planning and conducting experiments. The investigational experiments were conducted with five different process parameters serving as inputs: peak current, wire tension, wire feed rate, pulse on and off time. The response parameter measured was the slicing speed and the surface roughness. Further, comparisons were made between different kernel functions in support vector regression (SVR) for the prediction modelling of slicing speed and surface roughness. The difficulty in prediction modelling can be attributed to the complexity of the WEDM process, which is caused by the involvement of various process parameters. The primary purpose of this work is to determine the best predictive kernel among the linear, polynomial, radial basis function (Rbf), and sigmoid kernel functions based on the experimental data. The predictive performance of different kernel functions was evaluated and compared. Grid search was used for the hyper tuning of the kernel parameters. The radial basis function produces R2 of 99.751% and 97.552%, MSE values of 0.00046 and 0.00079, RSME values of 0.0215 and 0.02814, MAE values of 0.01645 and 0.01894, and MAPE values of 1.2% and 0.9% for slicing speed and surface roughness. Support vector regression with radial basis function gives better results in comparison to other kernel functions, which concludes that support vector regression with radial basis function is well suited for the prediction of slicing speed and surface roughness.

WEDM machining of MoNbTaTiZr refractory high entropy alloy

Refractory high entropy alloys (RHEAs) have shown great promise for a multitude of advanced engineering applications due to their high mechanical stability from cryogenic temperatures to 1600 °C. However, the low ductility they exhibit at room temperature limits their machinability when traditional machining techniques are used. Studies on the nontraditional machining of RHEAs, on the other hand, are very limited. In the present work, MoNbTaTiZr RHEAs subjected to wire electrical discharge machining (WEDM) were examined using electron microscopy, contact profilometry, and nanoindentation. Voids, microcracks, and recast material were observed on the machined surfaces. A transition from roughing to finishing decreased the amount of recast material, but the density of observable voids and microcracks on the surface increased. Optimal results were obtained by finishing, where the surface quality was improved by the removal of recast material remaining from prior passes. The brass wire electrode provided a smoother surface while the copper-core electrode provided minor heat-affected zone in the MoNbTaTiZr samples. In the roughing cuts, a 7.00% improvement in surface roughness was achieved using the copper-core electrode compared to the brass electrode. In the semi-finishing and finishing cuts, the brass wire electrode provided improvements of 13.68% and 22.68%, respectively, compared to the copper-core electrode. On the other hand, the wear of the brass electrode was as much as 20.98% higher than that of the copper-core electrode.

A New Wire Electrode for Improving the Machining Characteristics of High-Volume Fraction SiCp/Al Composite in WEDM.

In wire electrical discharge machining, due to the random distribution of the insulating SiC particles, frequent wire rupture, low machining efficiency and surface quality when the common brass wire electrode (BWE) is used to process high-volume content SiCp/Al composite often appears. To address this issue, this paper proposes a new preparation method of zinc coating and surface microstructure on wire electrodes (ZCSMWE). The preparation process of ZCSMWE includes casting, coating, annealing and plastic processing. The experimental results show that, compared with BWE, ZCSMWE can increase material removal rate (MRR) by 16.67%, reduce surface roughness (Ra) by 21.18% and reduce wire rupture under the same discharge parameters. The analysis of workpiece surface topography shows that ZCSMWE can significantly decrease the recast layer and microcrack on the machined surface. The improvement mechanism of ZCSMWE main includes: The low work function zinc can promote the forming of the discharge channel. The vaporization of low boiling temperature zinc can reduce the temperature of the discharge gap and promote the ejecting of workpiece material. In addition, the surface microstructure on ZCSMWE can make the discharge spark more uniformly distributed and increase the proportion of the effective discharge, which contributes to making the discharge crater on the workpiece and wire electrode shallower and more uniform. The surface microstructure on ZCSMWE can also effectively improve the dielectric circulation, which can promote discharge debris to be expelled out and reduce the temperature in the discharge gap. Then, the wire rupture and microcracks on the workpiece surface can be reduced.

Effect of wire material and discharge energy on productivity and surface integrity of WEDM-processed Inconel 718

ABSTRACT The current work aims to study the influence of discharge energy and debris accumulation on wire break failure and surface integrity aspects like surface roughness, subsurface hardness, and geometrical errors during the wire EDM of Inconel 718. The responses considered for analysing the geometrical accuracies are flatness error, roundness error and cylindricity error. Four different wire electrodes were considered for the study based on the wire strength and coatings, namely hard zinc coated brass, half-hard zinc coated brass, hard uncoated brass, and half-hard uncoated brass wire electrodes. The geometric accuracy of the machined parts is closely related to the choice of wire electrode. High-tensile strength hard wires were observed to machine the surfaces with maximum accuracy. Also, the zinc coated wires were observed to cut faster compared to the uncoated wire electrodes. The study revealed that there exists a strong influence of discharge energy on the surface integrity of wire electric discharge machined surface. The zinc and copper elemental contamination was minimal for uncoated wire electrodes at lowest discharge energy mode. Wire wear phenomena was analysed for both coated and uncoated wires. Discharge energy had a significant impact on the electrode wear of coated and uncoated wire electrode.

Investigation on wire electrical discharge machining of AISI 304 stainless steel

This paper presents an experimental investigation of the machining characteristics of the AISI304 stainless steel in the wire electrical discharge machining (WEDM) process. During experiments, parameters such as peak current, pulse on time, pulse off time, wire feed, and wire tension are varied to explore their effects on the response variables such as material removal rate and surface roughness. All the experimental runs have been conducted using a brass wire electrode. Taguchi L16 orthogonal array has been selected for designing the experimentation, and the principal component analysis (PCA) method is used to optimize the responses parameter. This study found that pulse on time is the most crucial factor influencing machining characteristics. It was also revealed that peak current and pulse off time impact surface roughness.

Machinability study of Incoloy using different wire electrode in Wire-Cut EDM

Increase in the usage of nickel-based superalloys in the field of aviation, marine industry, nuclear reactor due to its excellent mechanical properties like corrosive resistance, carburization resistance especially at elevated temperature. Nickel based superalloys are very tedious to machine in conventional because of high strength, less conductivity of thermal, strain hardening property. In this study, one of the best Unconventional machining processes i.e., Wire electric discharge machining is used for machining of Inconel 800 (Incoloy). Zinc coated brass wire; Cryogenic cooled zinc coated brass wire electrodes are used in Wire cut EDM. RSM technique is used to plan experiments with Wire tension, Pulse on time and Wire feed as varying parameters, keeping Servo voltage and Wire feed as constant. Material removal and Roughness of surface are compared for Zinc treated brass and Cryogenic cooled (LN2) Zinc treated brass and optimizing responses i.e., by using lower the better and higher the better criteria.

Experimental investigation and optimization of machining performance characteristics during WEDM of inconel 718: On evaluation of wire electrodes and advanced parameter techniques

Wire Electrical-Discharge-Machining (WEDM) is a well-known unconventional machining process to produce intricate shapes. However, obtaining a satisfactory WEDM cutting performance is indeed a challenging task during precision cutting. Hence, this investigation aims to attempt a favorable machining parameter setting in order to corner-cutting during WEDM for In-718. Here, machining performance characteristics have been considered based on corner deviation (CD) along with Material Removal Rate (MRR) and surface roughness (SR). Taguchi’s experiment design technique (L16) has been considered to run the experiments. The controllable process parameters are considered as Spark-on-time (Son), flushing-pressure (Fp), wire-tension (Tw), and discharge-current (Id). The aforesaid machining performance characteristics have been achieved through the two most popular wire electrodes, i.e., Zinc-coated brass electrode (Zn-BE) and Brass Wire Electrode (BWE), and compared the results. The comparison of performances by the wire electrodes on CD, MRR, and SR varied from 0.0286 mm to 0.0844 mm, 0.0045 g/min to 0.0214 g/min and 3.12 µm to 4.80 µm for BWE and 0.0218 mm to 0.0783 mm, 0.0090 g/min to 0.0342 g/min and 2.58 µm to 4.40 µm for Zn-BE respectively. However, machining with Zn-WE yields reduced CD, SR, and increased MRR value and shows less defect on the WEDMed surfaces than its counterpart. The present study developed the mathematical model based on non-linear regression for correlating the machining parameters with the machining responses. The next step of this study is that a unique optimization strategy, namely grey relation analysis (GRA) integrated with Teaching Learning-Based Optimization (TLBO), has been implemented for achieving optimal parametric setting. The satisfactory machining setting obtained from GRA-TLBO has been compared with GRA-JAYA and GRA-genetic algorithm (GA). The proposed methodology appears more fruitful in terms of computational time and effort.

Experimental investigation on WEDM performance analysis using grey-fuzzy integrated with TLBO algorithm for Inconel 625: comparison with GA and SA

Purpose In the present study, wire electro-discharge machining (WEDM) of Inconel 625 (In-625) is performed with the machining parameter such as spark-on time, spark-off time, wire-speed, wire tension and servo voltage. The purpose of this study is to find the most favorable machining parameter setting with respect to WEDM performance such as material removal rate (MRR) and surface roughness (RA). Design/methodology/approach Taguchi’s L27 orthogonal array has been used to design the experiments with varying machining parameters into three-level four factors. A hybrid multi-optimization technique has been purposed with grey relation analysis and fuzzy inference system integrated with teaching learning-based optimization to achieve optimum machinability (MRR and RA in present case). The obtained result has been compared with two evolutionary optimization tools via a genetic algorithm and simulated annealing. Findings It has been found that proposed hybrid technique taking minimum computational time, provide better solution and avoid priority weightage calculation by decision-makers. A confirmation test has been performed at single and multi-optimal parameter settings. The decision-makers have been chosen to select any single or multi-parameter setting as per the industry’s demand. Originality/value The proposed optimization technique provides better machinability of In-625 using zinc-coated brass wire electrode during WEDM operation.

Optimization of surface roughness by design of experiment techniques during wire EDM machining

Wire EDM technique has been often employed in fabricating electrically conductive difficult to cut metal complex shape components with high tolerance and precision. In WEDM process, generally employed conventional brass wire electrode is employed for machining operation. In this study we have employed zinc coated brass wire electrode for enhanced machining speed, accuracy, and precision. To investigate the variation in process parameters, i.e. peak current (Ip), pulse on time (Ton), pulse off time (Toff) and feed rate (FR) with optimization during WEDM machining operation. The obtained results have optimized by the Taguchi’s methodology. ANOVA analyses reveal critical factors for improvement of surface roughness. In this study, it was concluded that surface roughness increases with decrease in pulse off time, and spark gap set voltage. The surface roughness on the sample was enhanced with increase in Ton and IP.

Parametric optimization of silicon slicing using wire electro discharge machining

Abstract Silicon covers nearly about 90% of electronic sector that has made slicing a fundamental process for the manufacturing of various components such as integrated circuit, computer chips and solid-state devices. Silicon belong to the class of semi-conductor and has high brittleness due to which slicing using conventional machining processes is difficult, and many defects are to it such as chipping, scratches and large cracks. Wire Electro Discharge Machining (WEDM) is a potential process for slicing of silicon ingots. The present experimental investigation deals with the slicing of mono-crystalline silicon using WEDM process, using brass wire electrode of diameter 250 µm. The responses considered were material removal rate, surface roughness and slicing speed which were measured with the variation of the process parameters viz. open voltage(OV-V), servo voltage(SV-V), pulse on time (Ton -µs), wire tension(WT-g) and pulse off time(Toff -µs). The experimental runs were performed using Taguchi’s L27 (35) orthogonal design. The experimental results were analyzed using Taguchi based Grey Relational Analysis (TGRA) and the optimum parametric setting for the slicing was obtained at OV (111 V), Ton (0.2 µs), Toff (21 µs), WT (600 g) and SV (38 V). ANOVA analysis of the Grey Relational Grade (GRG) shows that pulse on time, wire tension and open voltage are the main contributing factor during slicing.

Multi-objective optimization of WEDM using cold treated brass wire for HSLA hardened steel

The present study analyzed the effects of cold treated brass wire electrode for the machining of hardened high-strength low-alloy (HSLA) steel on wire electric discharge machine. Cold treatment of brass wire at − 70 °C for 24 h has refined its microstructure which results in an increase in electrical conductivity by 24.5%. The experimental work is designed using fractional factorial design to determine the relationship of input variables including servo voltage (SV), pulse on time (Ton), pulse off time (Toff), wire type (Wt), wire tension (Tw), and flushing pressure (Fp) and response measures including cutting speed (CS), surface roughness (Ra), and kerf width (Kf). In Wt, two kinds of brass wires including cold treated (CT) and non-cold treated (NCT) have been used. Empirical models for cutting speed (CS), surface roughness (Ra), and kerf width (Kf) are developed, and their contribution is analyzed through the analysis of variance (ANOVA) technique. Desirability function offers the best combination of input variables to maximize CS and minimize both Ra and Kf simultaneously. Ton is observed as the most effective input variable for all response measures, followed by Wt and Toff. CT brass wire has been observed as the best alternative in multi-objective optimization.